Pressure-balanced battery for downhole tools

Abstract

Pressure-balanced primary and secondary batteries suited for supplying power to downhole tools and for powering a downhole telemetry network. The battery comprises an electrochemical generator disposed within at least a partially compliant enclosure or housing. The compliant enclosure permits pressurization of the electrochemical generator, thereby compensating for the increased temperature downhole. By permitting the electrochemical generator to be pressurized, the thermal range of the battery is extended to beyond 120.degree. C. The electrochemical generator comprises flexible components comprising an ionic conductor intermediate anode and cathode materials, a current collector, and a terminal. The battery may be installed within a recess in the wall of the downhole tool or within an annulus formed by the inside wall of the tool and a liner. In another embodiment of the invention, the battery may be located within an operative portion of a selected downhole tool, itself.

1. A pressure-balanced battery for downhole tools, comprising a compliant electrochemical cell disposed within at least a partially compliant enclosure of a downhole tool. 
     
     
       2. The battery of  claim 1 , wherein the compliant enclosure is in communication with downhole fluids. 
     
     
       3. The battery of  claim 1 , wherein the electrochemical cell comprises an ion conductor, anode and cathode materials, an electrolyte, a current collector and insulated conductors. 
     
     
       4. The battery of  claim 1 , wherein the electrochemical cell is in communication with at least one other electrochemical cell. 
     
     
       5. The battery of  claim 1 , wherein the electrochemical cell comprises a fluid electrolyte. 
     
     
       6. The battery of  claim 1 , wherein the electrochemical cell comprises a solid electrolyte. 
     
     
       7. The battery of  claim 1 , wherein the electrochemical cell comprises a fuel cell. 
     
     
       8. The battery of  claim 1 , wherein the electrochemical cell comprises a flexible casing. 
     
     
       9. The battery of  claim 1 , wherein the electrochemical cell is linked together with at least one other electrochemical cell, the electrochemical cells housed within a flexible casing having one of a generally polygonal shape, a generally cylindrical shape, and a generally semi-cylindrical shape. 
     
     
       10. The battery of  claim 1 , wherein the electrochemical cell is disposed-within a recess formed within the wall of a downhole tool. 
     
     
       11. The battery of  claim 1 , wherein the at least partially compliant enclosure comprises an annulus formed by an inside wall of a downhole tool and an outside wall of a compliant tool liner. 
     
     
       12. The battery of  claim 1 , wherein the electrochemical cell is in communication with a downhole network for transmitting electronic signals between downhole tools connected in a tool string. 
     
     
       13. The battery of  claim 1 , wherein the electrochemical cell is in communication with other downhole tools. 
     
     
       14. The battery of  claim 1 , wherein the electrochemical cell is in communication with a transmission ring connected to another transmission ring by means of a coaxial conductor. 
     
     
       15. The battery of  claim 1 , wherein the electrochemical cell is connected to an electronic module disposed within the downhole tool. 
     
     
       16. The battery of  claim 1 , wherein the electrochemical cell is rechargeable. 
     
     
       17. The battery of  claim 1 , wherein the battery has an operable range above 120 degrees C. 
     
     
       18. The battery of  claim 1 , wherein the battery is pressurized by ambient downhole pressures. 
     
     
       19. The battery of  claim 1 , wherein the enclosure is at least partially formed from at least one of a housing and a liner. 
     
     
       20. The battery of  claim 1 , wherein the enclosure is made of a material selected from the group consisting of steel, stainless steel, titanium, carbon composites, glass composites, and polymeric composites.